Staple forming and setting machine



Aug. 21, 1951 P. F. EPPLE EI'AL 2,564,336

STAPLE FORMING AND SETTING MACHINE Filed May 15, 1948 3 Sheets-Sheet 1F'IG.7

45 34/ mmvroxs.

PAUL E EPPLE 6 ROBERT I. PRUPIS .4 ATTOE EYS Aug. 21, 1951 P. F. EPPLEET AL ,886

STAPLE FORMING AND SETTING MACHINE Filed May 15, 1948 1 3 SheetsSheet 2J INVENTORS.

PAUL F. EPPLE I48 I46 ROBERT I. PEUPIS n40 nsa. T BY Z I2 I58 16a FIEJOl F'IEJI ATTORNEYS Aug. 21, 1951 P. F. EPPLE ET AL 2,564,886

STAPLE FORMING AND SETTING MACHINE Filed May 15, 1948 3 Sheets-Sheet 5INVENTORS. PAUL F. EPPLE ROBERT I. PEUPIS ATTOE Y5 Patented Aug. 21,1951 STAPLE FORMING AND SETTING MACHINE Paul F. Epple, Brooklyn, N. Y.,'and Robert I."

Prupis, Irvington, N. J., assignors to Conmar Products Corporationration oi New Jersey Newark, N. .L, a corpo- Application May 15, 1948,Serial No. 27,306

8 Claims. (Cl. 1-2) This invention relates to staple forming and settingmachines.

The primary object of the present invention is to generally improve suchmachines. A more particular object is to improve the staple forming andsetting machine disclosed in U. S. Patent #2,314,184, issued March 16,1943, to Rudolph E. Zeruneith. The machine in question is particularlyintended to make and apply end stops to slide fasteners. The end stop ispassed through the tapes of the slide fastener and clenched around theslide fastener elements, thus holding the lowermost elements in mutuallyinterlocked engagement.

In accordance with the present slide fastener sales practice, suchmachines are not sold to the user, but rather are given free by theslide fastener manufacturer, as a goodwill gesture. Because a largenumber of such machines must be made and distributed to customers at atotal loss, and without definite knowledge or promise as to the extentof slide fastener purchase by the customer, it is helpful to reduce thecost of making the machines. Accordingly an important object of thepresent invention is to greatly simplify the machine; to reduce itsweight; to minimize the castings required; to minimize the number ofsprings and other mechanical parts compared to those heretofore needed.In consequence we have. devised a staple forming and setting machinewhich has been so greatly simplifled that the cost of manufacture isonly a small fraction of what it was previously.

To accomplish the foregoing general objects, and other more specificobjects which will hereinafter appear, our invention resides in thestapling machine elements, and their relation one to another, as arehereinafter more particularly described in the following specification.The specification is accompanied by drawings in which Fig. 1 is aperspective view of one end of a flat wire from which the staples areformed;

Fig. 2 shows a staple blank cut from the continuous wire;

Fig. 3 shows the same after the forming operation;

Fig. 4 shows the staple as clenched around the slide fastener elements,but separated therefrom;

Fig. 5 shows where the clenched staple is applied in relation to theslide fastener;

Fig. 6 is a front elevation of a complete stapling machine embodyingfeatures of our invention;

Fig. 7 is a side elevation of the same;

Fig. 8 is a front elevation of the stapling head of the machine, with apart of the cover plate broken away;

Fig. 9 is a section taken in the plane of the line 9-9 of' Fig. 8;

Fig. 10 shows the stationary die, and the lower ends of the stapleformer and driver, drawn to enlarged scale;

Fig. 11 is a side elevation of the same, with a portion of the coverplate of the head also shown;

Fig. 12 is a horizontal section taken approximately in the plane of theline I2-l2 of Fig. 10.

Fig. 13 is a fragmentary view of the stationary die and wire guide, andis explanatory of a feature of the invention;

Fig. 14 is a section through the staple former taken approximately inthe plane of the line l4-|4 of Fig-11;

Fig. 15 is a rear elevation of the cover plate and the wire feedmechanism mounted thereon, with the cover plate removed from themachine;

Fig. 16 is a horizontal section taken approximately in the plane of theline l6l6 in Fig. 15;

Fig. 17 is an exploded view showing many of the working parts inperspective;

Fig. 18 is a bottom plan view of the slide with the attached driver andpusher dog shown in Fig. 17;

Fig. 19 is explanatory of a modification, and is a vertical sectionthrough the driver and cam block, much as is shown at one part of Fig.9; and

Fig. 20 is a horizontal section taken approximately in the plane of theline 20-40 in Fig. 6, to show the construction of the base of themachine.

Referring to the drawing, and more particularly to Figs. 1 through 5,the staples are formed from a reel of continuous flat wire, a piece ofwhich is indicated at I! in Fig. l. The point I at the end of the wireis formed by severance of the last preceding staple blank from the wire.The staple blank is shown at H5 in Fig. 2. The forward end 18 ispointed, and the trailing end 20 is bifurcated. These ends mate, thepointed end l8 of each staple being formed by the severance of thebifurcated end 20 of the preceding staple, without scrap or wastetherebetween.

The cutting operation is immediately followed by a forming operationwhich bends the blank to U shape, as is best shown in Fig. 3. In itscontinued downward movement the staple is forced through the tapes andis then clenched, it being forced against a suitable clenching anvil onwhich the slide fastener rests. At this time the points are bentinwardly, as is clearly shown in Fig. 4. The staple is not flattenedbecause it is preferably applied around the lowermost fastener elementsof the slide fastener, as is shown in Fig. 5. It will be understood thatthe slide fastener comprises tapes 22 and 24 hav-- ing interlockablefastener elements 26 and 28 secured along their respective beaded edges.The staple 30 acts as a bottom stop to limit downward motion of theslider (not shown) of the slide fastener. It also acts to hold thelowermost fastener elements in interlocked relation, thus preventingseparation of the stringers beneath the slider.

The stapling machine is shown in Figs. 6 and 7. It comprises a base B,an upright column C, and a stapling head H secured at the top of columnC. The mechanism of the stapling head H is operated by means of a foottreadle T.

As is best shown in Fig. 20, the base B comprises a pair of angle irons32 and 34, bent and secured together to form an extensive stable base. Aportion of the vertical flange 36 of angle iron 32 is secured to aportion of the. vertical flange 38 of the angle iron 34. The horizontalflanges 40 rest on the floor. In the particular form of base here showneach angle iron is bent once, and the two are secured together in Yshape.

The column 0 is made of a pair of upright members 42 and 44 which arearranged in collateral relation on opposite sides of the verticalflanges 36 and 38. The members are thus spaced apart somewhat by theflanges, and the operating arm 46 of treadle T is secured between themembers 42 and 44 in the space provided by the flanges 36 and 38. In thepresent case the members 42 and 44 are channel irons arranged inback-to-back relation. The treadle is pivoted at 48 by means of a pinpassing through the channels. Its rear end is bifurcated and receivesthe lower end of a generally upright link 50, the upper end of which isconnected to an operating arm 52 pivoted on the head H at 54. The linkis normally urged downwardly by means of a pull spring 56, thus raisingthe treadle T, and the mechanism within the stapling head.

In the particular structure here shown, a flat plate 58 of sheet steelis permanently secured to the top ends of channel irons 42 and 44, as bymeans of welding. receiving four bolts 60 by means of which the staplinghead H is removably secured to plate 58 and thus to the upright frame.It will be seen that the frame is inexpensive and light in weightcompared to a cast frame, for the angle irons of the base, and thechannel irons of the column, are all standard rolled stock commonlyavailable on the open market. The angle irons 32 and 34 areinexpensively secured together, and the channel irons 42 and 44 areinexpensively secured to the angle irons, by means of weldmg.

Coming now to the mechanism within the stapling head, and referring moreparticularly to Figs. 8, 9 and 1'7, there is a slide 62, the upper endof which is notched at 84 to receive the forward end 65 of the arm 52previously referred to. The slide 62 moves in ways 68 (see Fig. 17)formed at the forward end of a cast support 10, the said casting beingone of a very few parts in the entire machine which need be cast. Theslide 62 has a staple driver 12 secured therebeneath, as by means of apin I4, and these parts move together at all times. The slide 62 alsofunctions to move a staple outside former 10,

This plate has four holes but in this case the movement is at firstpositive, and later yieldable, through aspring 82 and plunger 84 shownin Fig. 17.

A part of the outside former acts also as a movable punch cooperatingwith a stationary die I48 (Fig. 8) to sever the blank from the wire,before the blank is bent to U shape around an inside former I20 (Fig. 9)by means of the outside former. The inside former then moves out of theway and the staple is carried downwardly by the outside former anddriver to the work on the stationary clenching anvil I68, where thestaple is clenched by the continued positive movement of the driver.

Considering'the mechanism in greater detail, the flat vnre stock iscarried on a reel I02 (see Figs. 6 and 7) freely rotatable on a rod I04carried at the upper end of an arm I08, the lower end of which issecured to the side of the cast head 10 previously referred to. Wirefrom the reel is fed downwardly to feed mechanism best shown in Figs. 15and 16. Fig. 15 is a rear view of the front plate I08 for the head ofthe machine. The wire I2 is fed through a guide hole III) and thencebetween a knurled feed wheel H2 and a pressure wheel H4. The wire thenpasses through a hollow guide tube II6 which is bent at II8 on a largeradius to feed the wire horizontally over the inside former I20. Theknurled feed wheel 2 is either made integrally with or is fixedlysecured to a suitable ratchet wheel I22. These parts are rotatable on ashaft I24, but are frictionally restrained against free movement bymeans of a relatively powerful compression spring I26 which urges thewheels against the inner face of the plate I08. The brake action causedby the spring restrains the feed wheels against overtravel by inertia.

The pressure wheel H4 is preferably a metal rimmed wheel having a rubbercore I28. This permits the wheel to yield, as is indicated by itseccentric relation to the shaft I30, shown in Figs. 15 and 16. Such apressure wheel may be built up specially, but we have found that astandard part commonly available in the commercial market for anotherpurpose. We refer to a Lord shockmount, the normal purpose of which isto so mount apparatus as to dampen vibration. It will be understood thatthe rubber portion I28 is disposed between inner and outer metalportions, the inner metal portion or hub rotating on the stationar shaftI30, and the outer metal portion or rim acting as a pressure wheelcoopcrating with the knurled feed wheel I I2.

The feed movement. is obtained by means of a pawl carried by the slide62 previously referred to, the said pawl being operative during theupward movement of the slide, and idling past the ratchet wheel duringdownward movement of the slide. The wire feed pawl is shown at I32 inFig. 17, it being received in a notch I34 in slide 62, and beingpivotally mounted on a pin I36. The corner I3! is cut away to permit thepawl to turn upwardly. The operative position of the pawl I32 is shownin phantom in Fig. 15. Its confinement between the slide and the coverplate I08 is shown in Fig. 9. In Fig. 8 the slide is in uppermostposition, and the pawl I32 comes to rest against stop surfaces I38. Asis best shown in Fig. 1'7, the stop surf aces I38 form the upper ends oflong recesses I40 formed in the forward edges of the ways 68 of the casthead 10. In Fig. 17 note the lower horizontal surface I42 at the bottomof notch I34 in slide 62. -This holds the pawl I32 in horizontalposition during upward movement of the slide after the pawl has beenturned downward about the pin I36.

It should be understood that as the slide moves downwardly the free endof the feed pawl I32 rises and moves idly past the ratchet wheel. At thelower end of the stroke the feed pawl is forced to horizontal position,if it has not fallen of itself to horizontal position, by contact of therear end of the feed pawl with the lower end I44 (Fig. 17) of notch I46.During upward movement of the slide the pawl remains in horizontalposition and engages a tooth of the ratchet wheel I22. In the presentcase the wheel has nine teeth and is moved one-ninth of a revolution bythe feed pawl. The feed is terminated when the slide reaches itsuppermost position, the feed pawl then being held in horizontal positionby the'horizontal surface I42 on the slide 62.

The flat wire is moved over a stationary die surface and is severed bythe action of a movable punch. Referring to Figs. 10, 11, 12 and'13, thetop of the die is indicated at I46, and the triangular portion whichcuts the notch or bifurcated end in the blank is shown at I46. These arein the lower portion of a stationary member I56 which extends upwardlyand acts as a guide at one side of the outside former I6. The triangularportion also extends upwardly, as indicated at I52, and its shape isbest shown in Fig. 12. To form the die surfaces I46 and I46 3. largenotch I54 is cut in the member I 56, as is best shown in Fig. 11. Thetop surface of die I46 is preferably ground at an angle or bias as isclearly shown in Fig. 10, "thus providing a shearing cut when the punchportion of the outside former reaches the wire I2 on the die. Thesection of Fig. 12 clearly shows how one side of the outside former I6is channeled to precisely flt the die, thereby acting as a shearingpunch as well as acting as a. staple former.

The centering of the wire laterallyof the die is controlled by means ofa flanged wheel I56 (Figs. 10 and 11). The top surface of die portionI46 is preferably ground on a curve, as is indicated at I56, to conformto the periphery of the wheel I66.

This permits the wheel to continue to effectively guide and center thewire I2 even after grinding away some of the top surface of the die tosharpen the same. This is indicated in Fig, 13 by the change from thedotted line surface I46 to the solid line surface I46, which changerepresents the amount that may be ground away in the course ofsucce-sive sharpenings before the guide wheel I56 will lose its guidingaction.

The sides of the flanges of the wheel are very slightly bevelled inorder not to shave the side edges of the wire. This bevel is shown inFig. 11,

III]

operation is performed by the outside former I6 surrounding the stapledriver I2. To move the outside former and punch I6 downwardly there is apusher dog I8 (Fig. 9) pivotally mounted on the slide 62, said dog inone of its positions having its lower end bearing on the top of theoutside former 16, as shown in Fig. 9, and in its other position passingby said outside former into the space indicated at 86. Fig. 1''! bestshows the spring 82 and pusher pin 84 which yieldably urge the outsideformer I6 downwardly even when the pusher dog I8 is disengaged. Thepusher pin 84 is also shown in Fig. 18. When the outside former I6 comesto rest against the clinching anvil to act as a staple guide while thedriver continues its positive downward movement, the former is held downby the spring 82 and pusher pin 64. To control the movement of thepusher dog a stationary camming pin 86 (Fig. 9) is provided, the saidpin preferably having a rounded tip and cooperating with the pusher dog,as is best shown in Fig. 9, to insure engagement with the outside formerwhen the slide is elevated. However, during the downward movement of theslide a sloping part 68 on dog I8 reaches and is pushed inwardly by thecamming pin 66, thereby moving the lower end of the pusher dog towardthe right, as viewed in Fig. 9, and so terminating the positiveengagement between the dog and the outside former.

The outside former I6 is disposed immediately around the staple driverI2, as is best shown in Fig. 12. The outside former bends the blank to Ushape around the inside former shown at I26 in Figs. 9 and 15. Theinside former is pivoted at I22, the pivot being so offset from theinside former that downward pressure on the inside former tends to causeit to swing outwardly out of the way of the staple driver. The insideformer comes between the sides of the staple former, as is best shown inFig. 14. The inside but it should be understood that the showing thereis greatly exag erated. and that in pract ce the bevel is so slight asnot to materially affect accurate feed of the wire as the die surface isground away.

The lateral or side-to-side position of the guide wheel may be adjusted,and for thispurpose the guide wheel is mounted on a stud the shank of'which is threadedly received in the die body I56.

former I26 to swing out of the way. This is after i the staple has beenformed, and permits the staple to be carried downwardly by the continuedmotion of the outside former and driver. Upon upward movement of thestaple driver the camming block 96 (and with it the outside former) iscarried upwardly by a pin 96 on the staple driver, as a result of whichthe inside former is moved back into position during the upper part ofthe stroke.

A modified arrangement for moving the camming block 96 is shown in Fig.19, in which it will be seen that the staple driver 98 is cut away atI66 to receive the camming block 96. The recess I66 is of such length asto afford a desired amount of lost motion between the upward anddownward movements of the camming block.

To prevent the bent staple from moving outwardly with the inside former,the outside former is preferably provided with steps, best shown at I64in Fig. 14. The staple driver and the staple occupy the full widthwithin the steps in the Outside former I6, which conforms to the outsidedimension of the staple. The inside former I26, however, conforms to theinside dimension of the staple. The steps correspond to the thickness ofthe staple blank, and accordingly restrain the staple against outwardmovement when the inside former I20 swings outwardly. The steps I64 alsohelp hold the staple firmly against tilting during the subsequent stapledriving and clenching operation. The material forming the steps I64 maybe milled away at a higher level, and this is indicated by the curveddotted line I66 in Fig. 11, the said line corresponding to the outlineof the milling cutter used in machining the outside former.

The clenching anvil is shown at I60 in Figs. 6, 7, 8 and 9. This is astationary member fixedly secured to a forwardly extending part I10 ofthe cast head I previously referred to. The anvil is provided with alocating pin I12. The tapes of the slide fastener are supported on theanvil, with the fastener elements brought as far as the pin "2, beforedepressing the treadle T to operate the machine. It will be understoodthat during the operation the outside former moves downwardly underspring pressure as far as the material of the slide fastener, and thenacts as a stationary guide for the staple. The staple driver I continuesits downward movement under positive downward pressure from the treadle,and forces the points of the staple through the fabric and against theconventional curved bending surfaces of the stationary clenching anvil.These turn the points inwardly, and finally the staple is clenchedtightly around the fastener elements.

When the treadle is released the restoring spring (56 in Fig. 7) pullsthe slide upwardly. ihis pulls the staple driver upwardly, and that inturn moves the camming block 90. The camming block 90 serves to take theoutside former l6 upwardly with it, the said block being seated in thenotches I14 best shown in Fig. 17. During the continued upward movementthe inside former I20 is moved back into position beneath the wire, thepusher dog I8 is forced back to a position above the outside former, andthe feed pawl feeds another unit length of wire forwardly over the dieand inside former.

Sometimes during the cutting operation a fine shred or sliver of metalmay remain on the side of the cutting punch. These slivers tend to bedrawn upwardly during the upward movement of the punch, and if notrelieved may accumulate, with increased friction and wearing action onthe punch. We accordingly provide a sliver escape passage. This passageis a hole I16 drilled through the front plate I08 and best shown inFigs. 11 and 15. A sloping top surface I18 (Figs. and 11) at the upperend of the die member I50 leads downwardly to the sliver escape passageI16. Upward movement of the punch tends to bring the slivers up to the.sloping surface I18, where they are deposited, and if they acc'umulatethe vibration of the machine during operation tends to shake them downinto the escape passage I16 where they can do no harm,- and from whichthey can escape.

The front plate I08 is secured to the cast head by means of two screwsI80, best shown in Figs. 8 and 15. There are also two locatin dowelsI82. The location of the screws and dowels is also indicated in Fig. 17.By simply removing the two screws I80 the front plate may be removed,thus exposing all of the internal mechanism for ready removal andexamination.

It is believed that the construction, assembly and operation of ourimproved stapling machine, as well as the advantages thereof, will beap- 8 parent from the foregoing detailed description. The machinerequires relatively few parts, and these are comparatively simple inconstruction and light in weight. Nearly all of the springs heretoforerequired have been eliminated, as well as numerous adjustmentsheretofore provided. The mechanism is so simple and fool-proof that itfunctions well over a long useful life without adjustment or repairother than an occasional grinding of the top surface of the stationarydie and the bottom surface of the punch. The assembly is simple andrapid, and the parts are readily accessible for examination or repair onremoval of only two screws. The machine may be built at only a smallfraction of the cost heretofore incurred. Despite the simplicity of themachine, many refinements are included, such as the biased die forprogressive shearing of the staple blank, the provision for sliverescape, the yieldable pressure on the wire at the feed wheel, thepositive control of the feed pawl for dimensional accuracy in the feedof the wire,

and so on.

It will be apparent that while we have shown and described our inventionin a preferred form, changes and modifications may be made, withoutdeparting from the spirit of the invention, as sought to be defined inthe following claims.

We claim:

1. In a staple forming and driving machine for forming staples out of astrip of flat wire, a stationary die, and guide means for guiding thewire accurately over the die, said guide means comprising a flangedroller, and adjustable means for rotatably carrying the roller includinga stud having a threaded shank carried by a threaded hole in themachine, whereby rotation of the stud adjusts the roller andconsequently the wire laterally for proper position over the die; andlocking means for fixing the rotational adjustment of the threaded stud.

2. In a staple forming and driving machine for forming staples out of astrip of flat wire, a stationary die having a grindable top surface, andguide means for guiding the wire accurately over the die, said guidemeans comprising a flanged roller, said roller being recessed into atrough on top of the die in order to accommodate sharpening or grindingof the top of the die.

3. In a staple forming and driving machine for forming staples out of astrip of fiat wire, a stationary die having a grindable top surfacesloping on a bias to produce a shearing cut, and guide means for guidingthe wire accurately over the die, said guide means comprising a flangedroller, said roller being recessed into an arcuate trough on top of thedie in order to improve the guiding action produced on the wire and inorder to accommodate sharpening or grinding of the top of the die.

4. In a staple forming and driving machine for forming staples out of astrip of fiat wire, a stationary die having a grindable top surface andguide means for guiding the wire accurately over the die, said guidemeans comprising a flanged roller carried by a threaded stud wherebyrotation of the stud adjusts the roller and consequently the wirelaterally for proper position over the die; and locking means for fixingthe adjustment of the threaded stud, said roller being recessed into atrough in order to accommodate sharpening or grinding of the top of thedie.

5. In a staple forming and driving machine for forming staples out of astrip of flat wire, a

asegese stationary die having a grindable top surface sloping on a biasto produce a shearing cut, and guide means for guiding the wireaccurately over the die, said guide means comprising a flanged rollercarried by a threaded stud whereby rotation of the stud adjusts theroller and consequently the wire laterally for proper position over thedie, and locking means for fixing the adjustment of the threaded stud,said roller being recessed into an arcuate trough in order to improvethe guiding action produced on the wire and in order to accommodatesharpening or grinding of the top of the die.

6. A staple forming and driving machine comprising a staple driver, anoutside former disposed around said driver, a stationary cutting diecooperating with a part of said outside former, a sliver escape passage,and an inclined surface alongside the cutting side of the outside formerand leading to said escape passage, to relieve any accumulation ofslivers resulting from use of the machine.

7. A stapling machine including guideways and a reciprocable slide formoving wire cutting, forming and driving means, and wire feed means tointermittently feed a wire to said cutting, forming and driving means,said wire feed means including a knurled feed wheel, a ratchet wheelcoaxial therewith for driving the same, a metal rimmed pressure rollercooperating with said knurled feed wheel, said pressure roller beingprovided with a rubber bushing for yieldability, and a feed pawl formoving said ratchet wheel, said feed pawl being so pivoted on said slidethat it tilts upwardly and idly passes the ratchet wheel during downwardmovement of the slide, but is positively arrested against downwardmovement during upward movement of the slide and engages a tooth of theratchet wheel, thus feeding the wire forwardly during upward movement ofthe slide.

8. A stapling machine including guideways and a reciprocable slide formoving wire cutting, forming and driving means, and wire feed means tointermittently feed a wire to said cutting, forming and driving means,said wire feed means including a knurled feed wheel, a ratchet wheelcoaxial therewith for driving the same, a compression spring for holdingsaid wheels frictionally against movement, a metal rimmed pressureroller cooperating with said knurled feed wheel, said pressure rollerbeing a rubber bushinged shockmount for yieldability, and a feed pawlfor moving said ratchet wheel, said feed pawl being so pivoted on saidslide that it tilts upwardly and idly passes the ratchet wheel duringdownward movement of the slide but is positively arrested againstdownward movement during upward movement of the slide and engages atooth of the ratchet wheel, thus feeding the wire forwardly duringupward movement of the slide.

PAUL F. EPPLE.

ROBERT I. PRUPIS.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 595,108 Levedahl Dec. 7, 1897999,372 Kempster Aug. 1, 1911 1,119,510 Heim Dec. 1, 1914 2,314,184Zeruneith Mar. 16, 1943 2,390,096 Goepfert Dec. 4, 1945

